High-speed print-and-apply label applicator

ABSTRACT

A high-speed print-and-apply label applicator includes a conveyor system, a control and monitoring system, a label web feeding assembly, a label printer and encoder system, and a tamp pad assembly driven by a linear motor having a shaft that is formed at least partially by a composite material. The tamp pad assembly includes a tamp pad having an upturned label ramp at the trailing edge of the tamp pad, an upturned anti-catch ramp at the leading edge of the tamp pad, and a flexible applicator. The flexible applicator may be secured to the leading edge of the tamp pad and extends at least partially over the generally horizontal surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 16/051,630, filed Aug. 1, 2018, titled “High-SpeedPrint-and-Apply Label Applicator,” which is a continuation-in-part ofU.S. patent application Ser. No. 15/788,623, filed Oct. 19, 2017, titled“High-Speed Print-and-Apply Label Applicator,” which claims priority toU.S. Provisional Patent Application No. 62/410,191, filed 19 Oct. 2016,“High-Speed Print-and-Apply Label Applicator,” all of which areincorporated herein by reference for all purposes.

BACKGROUND 1. Technical Field

The present application relates to a systems and methods for labelingpackages.

2. Description of Related Art

High-speed print-and-apply label applicator systems have been around formany years. These systems allow for high-speed labelling of packages asthe packages pass by on a continuous conveyer system. These labelapplicator systems generally consist of a control and monitoring system,a label printer and encoder system, a tamp assembly, and a conveyorsystem. The control and monitoring system monitors the system during thelabeling of packages and allows the operator to input commands and otheroperational parameters into the label applicator system. The labelprinter and encoder system prints and encodes the labels as directed bythe control and monitoring system. Packages are delivered to the tampassembly by the conveyor system, so that the tamp assembly can apply thelabels to the packages.

Currently the number of packages that can be processed in a giventimeframe is restricted by the speed of the tamp assembly. These labelapplicator systems are typically driven by pneumatic cylinders, rotarystepper motors, and/or rotary servo motors, all of which limit the speedat which the packages can be labelled. Although there have been greatstrides in the area of high-speed print-and-apply label applicatorsystems, significant shortcomings remain.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the system of the presentapplication are set forth in the present application. However, thesystem itself, as well as a preferred mode of use, and furtherobjectives and advantages thereof, will best be understood by referenceto the following detailed description when read in conjunction with theaccompanying drawings, wherein:

FIG. 1 is a schematic view of the preferred embodiment of a labelapplicator according to the present application;

FIG. 2 is a cut-away perspective view of a linear motor of the system ofFIG. 1;

FIG. 3 is a perspective view of a tamp pad assembly of the system ofFIG. 1 shown with the composite shaft in a retracted position;

FIG. 4 is a perspective view of another embodiment of a label applicatoraccording to the present application;

FIG. 5 is a perspective view of another embodiment of a label applicatoraccording to the present application showing the shaft of a linearactuator of the tamp pad assembly in an extended position;

FIG. 6 is an enlarged perspective view of a tamp pad assembly of theembodiment of FIGS. 4 and 5;

FIG. 7 is a perspective view of a very high-speed embodiment of a labelapplicator according to the present application;

FIG. 8 is a plan view of a transparent or translucent label for use inthe embodiment depicted in FIG. 7; and

FIG. 9 is an enlarged perspective view of an alternative embodiment of atamp pad assembly;

FIG. 10A is an enlarged perspective view of a tamp pad assembly of theembodiment of FIG. 9 in a first state; and

FIG. 10B is an enlarged perspective view of a tamp pad assembly of theembodiment of FIG. 9 in a second state.

While the system of the present application is susceptible to variousmodifications and alternative forms, specific embodiments thereof havebeen shown by way of example in the drawings and are herein described indetail. It should be understood, however, that the description herein ofspecific embodiments is not intended to limit the method to theparticular forms disclosed, but on the contrary, the intention is tocover all modifications, equivalents, combinations, and alternativesfalling within the spirit and scope of the present application.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Illustrative embodiments of the system of the present application aredescribed below. In the interest of clarity, not all features of anactual implementation are described in this specification. It will ofcourse be appreciated that in the development of any such actualembodiment, numerous implementation-specific decisions must be made toachieve the developer's specific goals, such as compliance withsystem-related and business-related constraints, which will vary fromone implementation to another. Moreover, it will be appreciated thatsuch a development effort might be complex and time-consuming, but wouldnevertheless be a routine undertaking for those of ordinary skill in theart having the benefit of this disclosure.

Reference may be made herein to the spatial relationships betweenvarious components and to the spatial orientation of various aspects ofcomponents as the devices are depicted in the attached drawings.However, as will be recognized by those skilled in the art after acomplete reading of the present application, the devices, members,apparatuses, etc. described herein may be positioned in any desiredorientation. Thus, the use of terms such as “above,” “below,” “upper,”“lower,” or other like terms to describe a spatial relationship betweenvarious components or to describe the spatial orientation of aspects ofsuch components should be understood to describe a relative relationshipbetween the components or a spatial orientation of aspects of suchcomponents, respectively, as the device described herein may be orientedin any desired direction.

The use of the term “package” is meant to mean any article, such as, butnot limited to, boxes, envelopes, containers, books, magazines, DVD's,CD's, and includes any item or article that can be placed on a conveyersystem and/or under a label tamp assembly for labeling purposes.

Referring now to FIG. 1 in the drawings, the preferred embodiment of ahigh-speed print-and-apply label applicator 100 according to the presentapplication is illustrated. Label applicator 100 allows for thehigh-speed printing and application of labels 102 from a web of labels110 onto packages 104. Packages 104 may be of the same size and shape,or as is shown, may be of various sizes and shapes. Label applicator 100includes a control and monitoring system 170, a label web feedingassembly 120, a label printer and encoder system 130, a label rejectionassembly 160, a tamp pad assembly 180, and a conveyor system 150.However, it will be appreciated that other embodiments of labelapplicator 100 may have more or fewer components. The components forlabel applicator 100 are preferably mounted or secured in a frameassembly 108. It will be appreciated that label applicator 100 may alsobe used in conjunction with a wide variety of package sorting machines,parcel management machines, and various other parcel encoding systems.

Control and monitoring system 170 of label applicator 100 allows for themonitoring and control of label applicator 100, and in some embodiments,also allows for the control and monitoring conveyor system 150, eitherdirectly or via communication with a system controller of conveyorsystem 150. It will be appreciated that control and monitoring system170 includes one or more monitors and/or displays, CPU's, ROM chips, RAMchips, USB ports, Ethernet and/or Internet connectivity, etc., and isconductively coupled to a user interface 172 and/or a system monitoringpanel 168. User interface 172 includes one or more switches, indicators,touch screens, keyboards, touchpads, and/or other input and/or outputdevices. It will be appreciated that user interface 172 may also beand/or include computers, tablet computers, remote controls, smartphones, and/or other personal handheld electronic devices. Systemmonitoring panel 168 includes of one or more air pressure gauges and/orother operational indicators. In some embodiments, users may accesscontrol and monitoring system 170 remotely, which may be conductedthrough a computer network, another computer, smart phone, tablet, otherlabel applicator systems, and/or other electronic devices.

Label web feeding assembly 120 preferably includes one or more supplyrolls 112, one or more guide rollers 122, one or more joining guiderollers 124, one or more drive and nip roller assemblies 126, and one ormore web rewind rolls 114. In addition to the components mentionedabove, other components may be used, depending upon the desiredapplication. Any of the aforementioned parts are capable of motorizationto facilitate the winding and unwinding of web 110 and/or the rewindingof scrap web 110 a. In the embodiment of FIG. 1, drive and nip rollerassembly 126 pulls scrap web 110 a, thereby causing web 110, along witha joined label 102 c, to pass around a peel tip 142 of a peeler member140. In embodiments that have labels 102 that require cutting, label webfeeding assembly 120 may include a cutting assembly operably associatedwith peeler member 140.

As shown in the embodiment of FIG. 1, label printer and encoder system130, also referred to herein as printer system 130, is preferably anRFID encoder and a thermal printer. However, in other embodimentsprinter system 130 may be a thermal printer, ink printer, other type ofprinter, and/or applicator. As shown in FIG. 1, labels 102 are RFIDlabels. However, in other embodiments it should be appreciated thatlabels 102 may be formed of paper, plastic, nylon, vinyl, or any othertype of suitable label materials. In the embodiment of FIG. 1, labels102 are discrete self-adhesive labels; however, other embodiments mayuse labels that require cutting and adhesive for fixation to thepackaging.

In some applications, a secondary label 102 b may be required. In suchapplications, secondary label 102 b is fed from a secondary label supplyroller 190 that feeds secondary label 102 b into printer system 130 forprinting and/or processing. A secondary label rewind roll 192 collectsthe secondary scrap web 194. Secondary label 102 b may be printed ornon-printed, and may be made of paper, plastic, nylon, vinyl, or anyother type of suitable label materials. In addition, secondary label 102b may include a printed or non-printed clear protective film. Printersystem 130 can print secondary label 102 b using any means such asthermal printing, ink or other method. Secondary label 102 b joins label102 a at joining guide roller 124, then joined label 102 c moves throughto an applicator system 131.

Applicator system 131 generally consists of peeler member 140 and peeltip 142, but may also include a label cutter, from which joined label102 c is separated from web 110. After separation, joined label 102 cwill either be taken up by label tamp assembly 180, or be received by alabel rejection assembly 160. Label rejection assembly 160 includes anaccumulation pad 162 and a label rejection driving mechanism 164.Accumulation pad 162 is where defective joined labels 102 c accumulate.Label rejection driving mechanism 164 may also include one or morelinear motors. Applicator system 131 may contain additional heatdissipating technology, either active or passive.

Tamp pad assembly 180 includes a linear motor 184, a slider shaft 186, atamp pad 182, an applicator plate 182 a. Tamp pad assembly 180 is ahigh-speed label application assembly that extends and retracts tamp pad182. Tamp pad assembly 180 may include one or more air intake hosesand/or fans located near tamp pad assembly 180 to provide air suction asrequired to hold labels as needed. In the preferred embodiment, tamp pad182 is formed from a polyurethane foam pad covered by and/or coated witha very thin sheet or layer of ultra-high-molecular-weight (UHMW)polyethylene material and/or coating to reduce friction and aid in therapid transfer of label 102 c to package 104.

Label applicator 100 includes a wide variety of sensors, probes, barcode readers, and/or scales to facilitate the processing and labeling ofpackages 104. As packages 104 travel along conveyor system 150, theweight, dimensions, and other physical parameters of each package 104,including the label height D1, D2, and D3, are determined by variousdimensioning sensors and other sensors. This package data is transmittedto control and monitoring system 170, which in turn, sends appropriatecontrol signals to linear motor 184.

Linear motor 184 is selectively configured to have a reduced mass and iscapable of moving shaft 186 at speeds of up to at least 7.3 meters persecond and at accelerations of over 780 meters per second squared. Thelinear motor available from LinMot™ under Part No. 0150-2549(PS01-37Sx60-HP-N-AGI) is particularly well suited for this application.Linear motor 184 slides along a high-performance slider. The slideravailable from LinMot™ under Part No, 0150-1510 (PL01-20x600/540-HP) isparticularly well suited for this application. Specifically, shaft 186is formed at least partially from a relatively lightweight,high-strength, composite material, preferably a carbon fiber material.This allows for very short positioning times and very high cycle rates.These performance characteristics far exceed those possible withprior-art systems. By utilizing linear motor 184 and selectivelyconfigured shaft 186, the height D1, D2, D3 of packages 104 may varyfrom 0″ to 18″. In addition, by utilizing linear motor 184, packages 104may be spaced more closely together than prior-art systems, primarilybecause of the speed, stroke capabilities, and other operationalparameters of the linear motor 184. By being able to space packagescloser together, increased package throughput is achieved. It will beappreciated that multiple linear motors may be utilized by system 100.Linear motor 184 may include various cooling and/or lubrication systemsand ensure that linear motor 184 operates reliably and efficiently.

In addition, linear motor 184 and/or shaft 186 may include one or moremagnetic springs and/or compression springs, such as a compressionspring 187, to assist in the deceleration of shaft 186 and applicatorplate 182 a as shaft 186 and applicator plate 182 a move upward towardthe resting position of shaft 186, and to assist in the efficientoperation of shaft 186 as shaft 186 moves through repeated strokecycles. Compression springs 187 may be located adjacent the home(retracted) position of shaft 186 or the lower (extended) position ofshaft 186. In addition, it will be appreciated that either linear motor184 or shaft 186, or both, may serve as the moving component in tamp padassembly 180. Accordingly, compression springs 187 may be locatedadjacent the home (retracted) position of linear motor 184 or the lower(extended) position of linear motor 184. Furthermore, compressionsprings 187 may be coupled directly to linear motor 184 and/or shaft186.

Referring now also to FIG. 2 in the drawings, linear motor 184 isillustrated. In the preferred embodiment, linear motor 184 has fourmajor components: a position and temperature sensors circuit board 201,a stator 203, a slider 205, and a payload mounting shaft 207. Tamp pad182 is preferably connected to shaft 207. Other embodiments might uselinear motors having different components.

The circuit board 201 measures and monitors the current position of thelinear motor 184, not only when linear motor 184 is stopped, but alsowhile linear motor 184 is in motion. Deviations in position are detectedimmediately and reported to the control and monitoring system 170.Slider 205 is preferably made of neodymium magnets that are mounted in ahigh-precision stainless steel tube. Stator 203 contains the motorwindings for slider 205. Position capture sensors and a microprocessorcircuit (not shown) for monitoring linear motor 184 are also part oflinear motor 184.

One unique feature of label applicator 100 is the configuration andmanner of operation of tamp pad assembly 180. Instead of moving shaft186 at the same acceleration and velocity each stroke, linear motor 184is configured such that the travel time of shaft 186 is the same foreach stroke of shaft 186. Thus, the acceleration and velocity of shaft186 varies dependent upon the vertical travel distance between the startposition of shaft 186 and the upper surface of each package 104. Inother words, tamp pad 182 moves from a start position, or firstposition, to the upper surface of each package 104 in the same amount oftime, regardless of the height D1, D2, or D3, i.e., regardless of thevertical travel distance of tamp pad 182. In the preferred embodiment,this selected travel time of shaft 186, also referred to herein as theactuation profile of shaft 186, is 150 ms. It will be appreciated, thatthe actuation profile may be varied from one operational session toanother. Selectively setting the actuation profile helps ensure thatlabel 102 c is placed onto each package 104 at a selected time and at aselected location.

In operation, the height D1, D2, and D3 of each package 104 is measured.Then, tamp pad assembly 180 actuates linear motor 184 and shaft 186according to the selected actuation profile. This results in each label102 c being accurately placed on each package 104 in a set amount oftime, preferably 150 ms.

FIGS. 4 and 5 depict another embodiment of a high-speed print-and-applylabel applicator 400 in accordance with the present application thatoperates in generally the same manner as described above. A spool holder401 may hold a spool of tightly wound labels (not shown). The spool oflabels may be unspooled over an idler roller 403 through a tension loop405, which keeps the spool tensioned while allowing the labels to be fedto the print engine 407. Print engine 407 prints the correct informationonto an individual label and then pulls the label across the labelseparator 409, which splits the label from the backing material,exposing the sticky, adhesive side of the label. The backing materialmay be spooled on roll 411. The label continues forward with itsmomentum and is forced up onto a tamp pad 500. The label is temporarilysecured on tamp pad 500 by suction or negative pressure that is producedin a plenum or box 413 of which tamp pad 500 forms the bottom surface,by a label suction fan 415 (as described in greater detail in connectionwith FIG. 6). Negative pressure from fan 415 may be applied to plenum413, and, when tamp pad 500 is in the retracted position to receive alabel, as shown in FIG. 4, vacuum may be applied through apertures intamp pad to hold the label onto the surface of tamp pad 500. Once theparcel that is to be labeled is in the correct location on the belt, theshaft 486 of linear actuator 480 moves, along with tamp pad 500 carryingthe label, to the correct height (D1, D2, or D3 from FIG. 1) and appliesthe label onto the parcel.

FIG. 6 illustrates tamp pad assembly 500, which comprises a tamp pad503, a label ramp 503A, and a flexible applicator 505. Tamp pad 503 andlabel ramp 503A preferably may be formed integrally, as a single pieceof machined or stamped metal or plastic to form a relatively rigidstructure that defines a generally horizontal surface for applyinglabels to parcels. Label ramp 503A is an upturned extension of pad 503and provides a smooth transition for the labels that come off of thelabel separator (409 in FIGS. 4 and 5). A first regularly spaced arrayof a plurality of oblong apertures 503B may be formed in tamp pad 503. Asecond array of regularly spaced circular apertures 503C may be formedin tamp pad 503.

A flexible applicator 505 may be generally coextensive with tamp pad 503and is attached to a leading edge 503D (leading in the sense that it isthe first edge to encounter a parcel moving in the direction of thearrow) of tamp pad 503 by screws, adhesive or other fasteners. Theunattached remainder of flexible applicator 505 may free to moverelative to tamp pad 503. The flexible applicator pad may be made of athin flexible material such as acetal polymer, that bends freely underinertial loads.

An array of oblong apertures 505B is formed in flexible applicator 505at locations corresponding to holes 503B in tamp pad 503, so that holes505B and 503B register or align with each other. Apertures 505B in theflexible applicator may be approximately 20% smaller in area thanapertures 503B in tamp pad 503. Apertures 503B and 503C in tamp pad 503apply suction, vacuum, or negative pressure to flexible applicator 505to hold it flush or flat against tamp pad 503 when it is in the fullyretracted position shown in FIG. 4, regardless of the presence of alabel. When a label is present on tamp pad assembly 500, the suction tothe label through registered apertures 503B and 505B is sufficient tohold both the label and flexible applicator 505 against tamp pad 503.

The operation of tamp pad assembly depicted in FIG. 6 is shown in FIG.5. In FIG. 5, label applicator 400 is shown with the shaft 486 of linearactuator 480 extended and decelerated immediately before contact with aparcel. Shaft 486 of linear actuator 480 slows or decelerates momentsbefore impacting the parcel, this change in momentum forces the flexibleapplicator pad 505 and the label to flex downwards. The parcel thenimpacts bent flexible applicator pad 505 and the label is applied byapplicator pad 505 as the parcel travels down the belt and past tamp padassembly 500. Linear actuator 480 then retracts shaft 486 and tamp padassembly 500 upward to plenum 413, and applicator pad 505 is retainedagainst tamp pad 503 by suction, vacuum, or negative pressure fromsuction fan assembly 415.

FIG. 7 illustrates an ultra-high-speed label applicator system 700according to an embodiment of the present application. System 700consists of two side-by-side high speed label applicators 701, 703. Eachhigh speed label applicators in this system 701, 703 is identical toapplicator 400 depicted in FIG. 4, but without a print engine, becausesystem 700 is configured for use with preprinted label to maximize speedat the expense of the flexibility associated with printing labels. Thealignment of the two high speed label applicators is such that there isa minimal gap between the actuators 780 and associated tamp pads. Theuse of two applicators side-by-side increases the throughput that thelabelers can handle. Placing the actuators side-by-side with a minimalgap between the tamp pads reduces the complexity and entropy in thetiming of the applicator system. Tracking and locating a parcel forapplying a label is simplified if the travel distance between actuatorsis minimized.

High-speed label applicator 700 may be configured to accept a roll ofpreprinted clear labels 800 illustrated in FIG. 8. Labels 800 aretransparent or at least translucent and have a sequential barcodeprinted in fluorescent or invisible ink. Clear labels 800 may be appliedto a parcel and any pre-existing important markings on the parcel(“TEXT”) to remain visible. Thus clear labels 800 permits unique labelsto be applied to parcels without affecting the readability of any of anymarkings on the parcels.

FIGS. 9-10B depict another embodiment of a tamp pad assembly 1000. Thetamp pad assembly 1000 includes magnets 902 embedded, inserted, orotherwise integrated with the tamp pad 903. Similar to previousembodiments, a label is temporarily secured on tamp pad 903 by suctionor negative pressure that is produced in a plenum of which tamp pad 903forms the bottom surface. Negative pressure from a fan may be applied tothe plenum, and, when tamp pad 903 is in the retracted position toreceive a label, as shown in FIG. 10A, vacuum may be applied throughapertures 903B and 905B in the tamp pad 903 to hold the label onto thesurface of tamp pad 903. Once the parcel that is to be labeled is in thecorrect location on the belt, the shaft 1086 of a linear actuator moves,along with tamp pad 903 carrying the label, to the correct height (D1,D2, or D3 from FIG. 1) and applies the label onto the parcel.

The tamp pad assembly 1000 comprises one or more permanent magnets 902,tamp pad 903, label ramp 903A, oblong apertures 903B, attachmentopenings 903C, edge 903D, anti-catch ramp 903E, and a flexibleapplicator 905. Preferably, the one or more permanent magnets 902comprise a pair of permanent magnets. Tamp pad 903, label ramp 903A, andanti-catch ramp 903E preferably may be formed integrally, as a singlepiece of machined or stamped metal or plastic to form a relatively rigidstructure that defines a generally horizontal surface for applyinglabels to parcels. Alternatively, at least the anti-catch ramp 903E isformed separately and is welded or otherwise attached to the tamp pad903. Label ramp 903A is an upturned extension of pad 903 and provides asmooth transition for the labels that come off of the label separator.The oblong apertures 903B comprise a regularly spaced array of aplurality of uniformly dimensioned oblong apertures that may be formedin tamp pad 903 (FIG. 10B). Alternatively, the apertures 903B areirregularly spaced and non-uniform in dimension, being formed in theshape of logos, symbols, or other desired shapes. Anti-catch ramp 903Eis another upturned extension disposed opposite the label ramp 903A andpreferably is larger in size and/or dimensions than the label ramp 903A.The anti-catch ramp 903E is configured to prevent parcels from catchingor getting stuck on tamp pad 903. Alternatively, the label ramp 903A isequal in size or slightly larger than the anti-catch ramp 903E to enablea smooth transition from the label printer to a flexible applicator 905.

The flexible applicator 905 may be generally coextensive with tamp pad903 and is attached to abut an edge 903D. The edge 903D is a leadingedge relative to the edges of the label ramp 903A, being the first edgeto encounter a parcel moving in the direction of the arrow. The end ofthe flexible applicator 905 that abuts the edge 903D is attached to thetamp pad 903 by screws, adhesive, and/or other fasteners. The unattachedremainder of flexible applicator 905 may be free to move relative totamp pad 903. The flexible applicator 905 is preferably made of springsteel. Alternatively, other thin, flexible materials that bend freelyunder inertial loads, such as plastic, elastomeric compounds, orcombinations thereof, may be used. In these embodiments, a metal wire,mesh, or washer may be embedded, inserted, or otherwise integrated intothe flexible materials to interact with the permanent magnets 902.

The array of oblong apertures 905B is formed in the flexible applicator905 at locations corresponding to holes 903B in tamp pad 903, so thatapertures 905B and holes 903B register or align with each other.Apertures 905B in the flexible applicator 905 may be approximately10-20% smaller in area than holes 903B in tamp pad 903.

Preferably the tamp pad 903 depicted in FIGS. 9-10B has a continuousperimeter around the tamp pad 903, the label ramp 903A, and theanti-catch ramp 903E. Alternatively, discrete fingers are formed in atleast the back end 904 of the tamp pad 903. In at least one embodiment,the discrete fingers are formed in both ends of the tamp pad 903. Forexample, the oblong openings 903B and/or openings 906 of the anti-catchramp 903E extend through to the perimeter, forming discrete fingers inthe label ramp 903A, the anti-catch ramp 903E, and/or the back end 904of the tamp pad 903. Embodiments having discrete fingers formed in thetamp pad 903 preferably have the fingers formed in the back end 904.Preferably, the discrete fingers disposed in the back end 904 of thetamp pad 903 have inner slots, holes, or apertures formed therein forapplying suction to the back end of the tamp pad 903.

The operation of tamp pad assembly 1000 is shown in FIGS. 10A and 10B.In FIG. 10A, tamp pad assembly 1000 is shown with the shaft 1086 of alinear actuator extended. Permanent magnets 902 are disposed in at leastthe back end 904 of the tamp pad 903 to retain the flexible applicator905 after it receives an inertial force from a downward thrust of theshaft 1086. For example, permanent magnets 902 may apply magnetic forceto flexible applicator 905 to hold it flush or flat against tamp pad 903when the tamp pad is in the fully retracted position shown in FIG. 10A,regardless of the presence of a label. When a label is present on tamppad assembly 1000, suction is applied to the label through registeredapertures 903B and 905B sufficient to hold the label against tamp pad903.

In FIG. 10B, the shaft 1086 of the linear actuator slows or deceleratesmoments before impacting the parcel, changing momentum fromdeceleration. A change in momentum removes the flexible applicator 905from the permanent magnets 902, releasing the flexible applicator 905,just before impact. For example, as the shaft 1086 is slowed or stopped,the change in momentum of the tamp pad assembly 1000 at the end of theshaft 1086 forces the flexible applicator 905 and the label to flexdownwards. The parcel then impacts bent flexible applicator 905 and thelabel is applied by applicator 905 as the parcel travels down the beltand past tamp pad assembly 1000. The linear actuator then retracts shaft1086 and tamp pad assembly 1000 upward to the plenum, and the flexibleapplicator 905 is again retained against tamp pad 903 by the permanentmagnets 902 and/or the suction, vacuum, or negative pressure from asuction fan assembly. Fasteners 1008 are ultra-flush and/or are lessthan or equal to a height of the edge 1003D, such that parcels are notdamaged by the fasteners 1008.

Alternatively, permanent magnets 902 are replaced by, or used togetherwith, electro-magnets. For example, one or more electro-magnets 902 mayreceive a first electric current to apply magnetic force to flexibleapplicator 905 to hold it flush or flat against tamp pad 903 when thetamp pad is in the fully retracted position shown in FIG. 10A,regardless of the presence of a label. When a label is present on tamppad assembly 1000, suction is applied to the label through registeredapertures 903B and 905B sufficient to hold the label against tamp pad903

In FIG. 10B, the shaft 1086 of the linear actuator slows or deceleratesmoments before impacting the parcel, and a second electric force(repulsive, or oppositely charged) is applied or the first electricforce is removed from the one or more electro-magnets 902, releasing theflexible applicator 905, just before impact. The second electric force,and/or the change in momentum, forces the flexible applicator 905 andthe label to flex downwards. The parcel then impacts bent flexibleapplicator 905 and the label is applied by applicator 905 as the parceltravels down the belt and past tamp pad assembly 1000. The linearactuator then retracts shaft 1086 and tamp pad assembly 1000 upwardtowards the linear actuator, and flexible applicator 905 is retainedagainst tamp pad 903 by the electro-magnet(s) 902 receiving the firstelectric current again and/or the suction, vacuum, or negative pressurefrom a suction fan assembly.

The particular embodiments disclosed above are illustrative only, as theapplication may be modified and practiced in different but equivalentmanners apparent to those skilled in the art having the benefit of theteachings herein. Furthermore, no limitations are intended to thedetails of construction or design herein shown, other than as describedin the claims below. It is therefore evident that the particularembodiments disclosed above may be altered, combined, and/or modified,and all such variations are considered within the scope and spirit ofthe application. Accordingly, the protection sought herein is as setforth in the claims below. It is apparent that a system with significantadvantages has been described and illustrated. Although the system ofthe present application is shown in a limited number of forms, it is notlimited to just these forms, but is amenable to various changes andmodifications without departing from the spirit thereof.

I claim:
 1. A tamp pad assembly for a high-speed label applicator, ashaft extended and retracted by an actuator; a tamp pad coupled to theshaft, the tamp pad having a generally horizontal surface with a leadingedge; an upturned label ramp at the leading edge of the tamp pad; and aflexible applicator secured to the leading edge of the tamp pad andextending at least partially over the generally horizontal surface; aplurality of permanent magnets disposed in the tamp pad, wherein, uponexperiencing a change in momentum of the tamp pad assembly, the flexibleapplicator is held against the horizontal surface of the tamp pad. 2.The tamp pad assembly according to claim 1, further comprising: aplurality of tamp pad apertures formed in the tamp pad, wherein, uponapplication of negative pressure to the tamp pad apertures, a label isheld against the flexible applicator of the tamp pad.
 3. The tamp padassembly according to claim 2, further comprising: a vacuum sourceoperably connected to the tamp pad to apply negative pressure to thetamp pad apertures and to at least one of the label and the flexibleapplicator when the shaft and tamp pad are in a retracted position. 4.The tamp pad assembly according to claim 1, further comprising: aplurality of applicator apertures formed in the flexible applicator; aplurality of first tamp pad apertures, the first tamp pad aperturesapplying suction to the applicator; and a plurality of second tamp padapertures, larger in area than the applicator apertures, wherein theapplicator apertures register with the second tamp pad apertures toapply suction to a label on the applicator.
 5. The tamp pad assemblyaccording to claim 4, further comprising: a vacuum source operablyconnected to the tamp pad to apply negative pressure to the first andsecond tamp pad apertures.
 6. A tamp pad assembly for a high-speed labelapplicator, the tamp pad assembly comprising: a shaft extended andretracted by an actuator; a tamp pad coupled to the shaft, the tamp padhaving a generally horizontal surface with a leading edge; an upturnedlabel ramp at the leading edge of the tamp pad; and a flexibleapplicator secured to the leading edge of the tamp pad and extending atleast partially over the generally horizontal surface; wherein theflexible applicator is made of spring steel and is configured to moverelative to the tamp pad as the shaft extends and retracts.
 7. The tamppad assembly according to claim 6, further comprising: a second shaftextended and retracted by an actuator; a second tamp pad coupled to theshaft, the tamp pad having a generally horizontal surface with a leadingedge; and a second flexible applicator secured to the leading edge ofthe second tamp pad and extending at least partially over the generallyhorizontal surface, wherein the shafts, tamp pads, and flexibleapplicators are minimally spaced apart.
 8. A tamp pad assembly for ahigh-speed label applicator, the tamp pad assembly comprising: a shaftextended and retracted by an actuator; a tamp pad coupled to the shaft,the tamp pad having a generally horizontal surface with a leading edge;an upturned label ramp at the leading edge of the tamp pad; and aflexible applicator secured to the leading edge of the tamp pad andextending at least partially over the generally horizontal surface; ananti-catch ramp disposed on the tamp pad opposite the label ramp.
 9. Ahigh-speed print-and-apply label applicator, comprising: a control andmonitoring system; a label web feeding assembly; a conveyor system forconveying one or more packages; and a tamp pad assembly comprising: ashaft moved between extended and retracted positions by an actuator; anda tamp pad coupled to the shaft, the tamp pad having a generallyhorizontal surface having a leading edge; an upturned anti-catch ramp atthe leading edge of the tamp pad; and a flexible applicator secured toabut the leading edge of the tamp pad and extending at least partiallyover the generally horizontal surface.
 10. The label applicatoraccording to claim 9, further comprising: a plurality of electro-magnetsdisposed in the tamp pad, wherein, upon application of an electriccurrent to the electro-magnets, the flexible applicator is released fromthe horizontal surface of the tamp pad.
 11. The label applicatoraccording to claim 9, wherein the flexible applicator is generallycoextensive with the horizontal surface of the tamp pad.
 12. The labelapplicator according to claim 9, further comprising: a plurality of tamppad apertures formed in the tamp pad, wherein, upon application ofnegative pressure to the tamp pad apertures, the applicator is heldagainst the horizontal surface of the tamp pad.
 13. The label actuatoraccording to claim 12, further comprising: a vacuum source operablyconnected to the tamp pad to apply negative pressure to the tamp padapertures and to the flexible applicator when the shaft and tamp pad arein a retracted position.
 14. The label applicator according to claim 9,further comprising: a plurality of applicator apertures formed in theflexible applicator; a plurality of first tamp pad apertures, the firsttamp pad apertures applying suction to the flexible applicator; and aplurality of second tamp pad apertures, larger in area than theapplicator apertures, wherein the applicator apertures register with thesecond tamp pad apertures to apply suction to a label on the flexibleapplicator.
 15. The label actuator according to claim 14, furthercomprising: a vacuum source operably connected to the tamp pad to applynegative pressure to the first and second tamp pad apertures.
 16. Thetamp pad assembly according to claim 9, wherein the flexible applicatoris made of spring steel; and wherein inertia as the shaft extends andretracts moves the flexible applicator relative to the tamp pad.
 17. Thetamp pad assembly according to claim 9, further comprising: a secondshaft extended and retracted by an actuator; a second tamp pad coupledto the shaft, the tamp pad having a generally horizontal surface with aleading edge; and a second flexible applicator secured to the leadingedge of the second tamp pad and extending at least partially over thegenerally horizontal surface, wherein the shafts, tamp pads, andflexible applicators are minimally spaced apart.
 18. The tamp padassembly according to claim 9, wherein labels applied by the flexibleapplicator are at least partially transparent.
 19. The tamp pad assemblyaccording to claim 9, further comprising: a second shaft extended andretracted by an actuator; a second tamp pad coupled to the shaft, thetamp pad having a generally horizontal surface with a leading edge; anda second flexible applicator secured to the leading edge of the secondtamp pad and extending at least partially over the generally horizontalsurface, wherein the shafts, tamp pads, and flexible applicators areminimally spaced apart.
 20. The tamp pad assembly according to claim 8,further comprising: a second shaft extended and retracted by anactuator; a second tamp pad coupled to the shaft, the tamp pad having agenerally horizontal surface with a leading edge; and a second flexibleapplicator secured to the leading edge of the second tamp pad andextending at least partially over the generally horizontal surface,wherein the shafts, tamp pads, and flexible applicators are minimallyspaced apart.